U.S. patent application number 10/076916 was filed with the patent office on 2003-08-14 for apparatus and method for forming a mold.
Invention is credited to Pelletier, Martin.
Application Number | 20030151163 10/076916 |
Document ID | / |
Family ID | 27660254 |
Filed Date | 2003-08-14 |
United States Patent
Application |
20030151163 |
Kind Code |
A1 |
Pelletier, Martin |
August 14, 2003 |
Apparatus and method for forming a mold
Abstract
An apparatus and process for manufacturing a mold with a
reusable material. The apparatus having a heating basin, a pump for
pumping the liquefied heat sensitive pliable substance out from the
heating basin and into a cooler. The heat sensitive pliable
substance is injected in a forming tool according to a definite
path in order to form a mould.
Inventors: |
Pelletier, Martin;
(Loretteville, CA) |
Correspondence
Address: |
MR. S. PETER LUDWIG
DARBY & DARBY P.C.
805 THIRD AVENUE
NEWYORK
NY
10022
US
|
Family ID: |
27660254 |
Appl. No.: |
10/076916 |
Filed: |
February 14, 2002 |
Current U.S.
Class: |
264/219 ;
425/175 |
Current CPC
Class: |
B29C 31/044 20130101;
B29K 2091/00 20130101; B29C 48/12 20190201; B29C 41/003 20130101;
B29C 48/302 20190201; B29C 64/314 20170801; B29C 48/05 20190201;
B29C 33/3842 20130101; B29C 48/06 20190201 |
Class at
Publication: |
264/219 ;
425/175 |
International
Class: |
B29C 033/40 |
Claims
1. An apparatus for manufacturing a mold, the apparatus comprising:
a heating basin for liquefying and maintaining a heat sensitive
pliable substance in a liquid form; a pump for pumping out from the
heating basin the liquefied heat sensitive pliable substance; a
cooler for receiving and cooling the heat sensitive pliable
substance pumped out of the heating basin to a predetermined
texture; an applicator for ejecting the heat sensitive pliable
substance out from the apparatus and into a forming tool; and a
positioning system for moving the applicator and for building a
mold by successive application of a formed thread of heat sensitive
pliable substance.
2. An apparatus according to claim 1, wherein the heat sensitive
pliable substance is selected from the group consisting of wax and
any other malleable plastic.
3. An apparatus according to claim 1, wherein the heating basin
comprises a heat exchanger.
4. An apparatus according to claim 3, wherein the heat exchanger is
an electrical heating element.
5. An apparatus according to claim 3, wherein the heat exchanger is
a hot fluid circulating system.
6. An apparatus according to claim 1, wherein the pump further
includes a heating device.
7. An apparatus according to claim 1, wherein the cooler is in the
shape of a longitudinal flexible tube, the tube having a diameter
of less than 4 mm.
8. An apparatus according to claim 1, wherein the cooler comprises
a coil tube submerged in a cooling fluid.
9. An apparatus according to claim 1, wherein the applicator is
connected to a forming tool for projecting and directing the heat
sensitive pliable substance on the mold.
10. An apparatus according to claim 1, wherein the forming tool is
a nozzle adapted to extrude various shape of thread by modifying
the angle from the direction of the movement of the applicator.
11. A process for producing a heat sensitive pliable mold, the
process comprising the steps of a) selecting a heat sensitive
pliable substance, b) liquefying the heat sensitive pliable
substance to obtain a liquid substance, c) cooling the liquid
substance to obtain a semi-rigid substance, and d) applying the
semi-rigid substance obtained in step c) with an applicator so as
to allow the heat sensitive pliable substance to harden into a
definite shape and thereby form a mold.
12. A process according to claim 11, further comprising the step of
melting the mold obtained in d) in a heating basin for the
manufacture of a new mold.
13. A process according to claim 11, further comprising the step of
melting the mold outside the basin and pumping the liquid heat
sensitive substance in the heating basin.
14. A process according to claim 11, wherein the molding step d)
comprises extruding the semi-rigid substance through a forming
tool.
15. A process according to claim 9, wherein the heat sensitive
pliable substance is selected from the group consisting of wax and
any other malleable plastic.
16. A process according to claim 14, wherein the forming tool is
adapted to extrude thread with various curvature by modifying the
angle from the direction of the movement of the applicator.
17. A process according to claim 11, wherein the molding step d)
comprises moving the applicator along a three dimension path and
applying the thread side by side and overcoating the path.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus and a process
for manufacturing a mold,
BACKGROUND OF THE INVENTION
[0002] Molds having different shape and size exist for moulding
different pieces of various composite materials. Each of these
molds is used for molding a piece of composite material in a unique
shape and size. They may not be reused for molding a piece of
another shape and size. Therefore, there is a need to produce
different types of molds for different required dimensions The main
inconvenience with such a molding process is related to the high
cost of the material needed to carry out the process and the time
that is needed to prepare such material.
[0003] U.S. Pat. No. 4,929,403 is concerned with a process for
forming a flexible mold for finely detailed objects from a
radiatively curable molding composition. The molding composition
includes coating at least a portion of the surface of a
three-dimensional object. The coating is cured by exposing the
fluid coating to radiative energy to form an elastic, flexible
layer of cured molding composition on the object.
[0004] Therefor there is a need to provide a simple apparatus and
process for manufacturing a mold with a reusable material.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to provide an
apparatus and method for manufacturing a mold.
[0006] Another object of the present invention is to provide an
apparatus and method for manufacturing a mold with a reusable
material.
[0007] In accordance with the present invention, these objects are
achieved with an apparatus for manufacturing a mold, the apparatus
comprising:
[0008] a heating basin for liquefying and maintaining a heat
sensitive pliable substance in a liquid form;
[0009] a pump for pumping out from the heating basin the liquefied
heat sensitive pliable substance;
[0010] a cooler for receiving and cooling the heat sensitive
pliable substance pumped out of the heating basin to a
predetermined texture;
[0011] an applicator for ejecting the heat sensitive pliable
substance out from the apparatus and into a forming tool; and
[0012] a positioning system for moving the applicator and for
building a mold by successive application of a formed thread of
heat sensitive pliable substance.
[0013] Also in accordance with the present invention, there is
provided a process for producing a mold with a reusable material,
the process comprising the steps of:
[0014] a) selecting a heat sensitive pliable substance,
[0015] b) liquefying the heat sensitive pliable substance to obtain
a liquid substance,
[0016] c) cooling the liquid substance to obtain a semi-rigid
substance, and
[0017] d) applying the semi-rigid substance obtained in step c)
with a forming tool so as to allow the heat sensitive pliable
substance to harden into a definite shape and thereby form a
mold.
[0018] An advantage provided by the apparatus and method of the
present invention is that it allows the manufacture of molds in a
wide variety of shape and sizes with the same amount of molding
material. This in turn, significantly reduces the cost of mould
manufacture.
[0019] Another advantage of using a heat sensitive pliable
substance as the base for the mold is that it is possible to
create, with the same load of substance, various sets of moulds
having different shapes and sizes in little time. Furthermore,
since the substance may be reused to form other moulds, little
waste is generated.
[0020] Furthermore, the process of the present invention allows the
manufacture of a small number of reinforced plastic pieces (1 to 5)
in a short time and at very low cost,
[0021] The present invention and its advantages will be more easily
understood after reading the following non-restrictive description
of preferred embodiments thereof, made with reference to the
hereinbelow drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a general overview of the apparatus according to a
preferred embodiment of the present invention.
[0023] FIG. 2 is a side view of a portion of the apparatus of FIG.
1.
[0024] FIG. 3 is a schematic representation of the path along which
the heat sensitive pliable substance is applied from the apparatus
of FIG. 1
[0025] FIG. 4 is a schematic representation of a forming tool.
DETAILED DESCRIPTION OF THE INVENTION
[0026] As seen in FIG. 1, the present invention relates to an
apparatus for manufacturing a mold with a reusable material. The
apparatus comprises a heating basin 3; a pump 5; a cooler 7; and an
applicator 9, The heating basin 3 is designed to liquefy and
maintain a heat sensitive pliable substance in a liquid form. The
heating basin 3 may comprise a heat exchanger such as an electrical
heating element or a hot fluid circulating system. It should be
understood that any other heating devices suitable for use in the
context of the present invention may be used.
[0027] The pump 5 is used to pump the liquefied heat sensitive
pliable substance out from the heating basin 3 and into a cooler.
According to a preferred embodiment, the pump 5 may further include
a heating device. This heating device would help to maintain the
heat sensitive pliable substance in an appropriate state, generally
liquid, prior to reaching the cooler. In the context of the present
invention, it is important that the heat-sensitive pliable
substance does not solidify too quickly prior to reaching the
cooler since it would cause obstruction of the apparatus.
[0028] The cooler 7 is designed for receiving and cooling the heat
sensitive pliable substance pumped out of the heating basin 3 to a
predetermined texture. The heat sensitive pliable substance is
cooled down in order to reach a predetermined state that is between
the liquid and solid state. In a preferred embodiment, the cooler 7
is in the shape of a longitudinal flexible tube, the tube having a
diameter of less than 4 mm. Once the substance is cooled down and
reaches the predetermined texture, it is pumped to the applicator
9. Again, any cooling device that may enable the cooling of the of
the heat sensitive pliable substance may be used in the context of
the present invention. For instance, the cooler may comprise a coil
of tube submerged in a cooling fluid.
[0029] The applicator 9 may be mounted on a positioning system
having 6 degrees of freedom.
[0030] The applicator 9 of the apparatus of the present invention
ejects the heat sensitive pliable substance out from the apparatus
and on the mould. The applicator 9 may be connected to a forming
tool for projecting and directing and forming the heat sensitive
pliable substance on the mold.
[0031] The heat sensitive pliable substance that may be used in the
context of the present invention may be a substance selected from
the group consisting of wax and any other malleable plastic.
[0032] The present invention also relates to a process for
producing a mold with a reusable material. The process comprises
the steps of;
[0033] a) selecting a heat sensitive pliable substance,
[0034] b) liquefying the heat sensitive pliable substance to obtain
a liquid substance,
[0035] c) cooling the liquid substance to obtain a semi-rigid
substance, and
[0036] d) applying the semi-rigid substance obtained in step c)
with an applicator so as to allow the heat sensitive pliable
substance to harden into a definite shape and thereby form a
mold.
[0037] In a preferred embodiment, step d) comprises extruding the
semi-rigid substance through a forming tool which may be a nozzle.
The substance is extruded according to a definite path.
[0038] The process of the present invention may further comprise a
step whereby the mold obtained in d) is melted in the heating basin
for the manufacture of a new mold.
[0039] In use, the mould is produced by successive application of a
formed thread of heat sensitive pliable substance according to a
definite path. FIG. 3 show an example of a path to build a plane
layer of a mold, A complete mold is produced by superposition of
multiple layers. The thread is formed by the forming tool installed
on the applicator. The forming tool is a specially shaped nozzle.
The forming tool as shown in FIG. 4 allow to extrude thread with
various curvature by modifying the angle relative to the direction
of the movement of the applicator. As the substance is applied, it
hardens into the shape of the mold.
[0040] As can be seen in FIG. 3, and the above description of the
molding process is a simplified illustration of the actual process.
Normally, the path is in three dimension.
[0041] The mold manufacture according to the present invention may
be reused in order to form a new mold having a different shape and
size. More precisely, the mold which is made of heat-sensitive
pliable substance may be placed in the heating basin. It is then
melted inside the heating basin. When the heat sensitive pliable
substance reaches the liquid state, a new cycle for the manufacture
of a new mold begins.
[0042] In an alternative embodiment, the mold can be melted outside
of the heating basin and pumped into the basin.
[0043] Although the present invention has been explained
hereinabove by way of a preferred embodiment thereof, it should be
pointed out that any modifications to this preferred embodiment
within the scope of the present invention is not deemed to alter or
change the nature and scope of the present invention.
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